Damped brake components and methods of manufacturing the same

ABSTRACT

A brake component may include a body and at least one sheathed cable positioned within the body. The at least one sheathed cable may include a plurality of wires, each of the plurality of wires having a surface in sliding contact with a surface of at least one adjacent wire of the plurality of wires. During braking of the motor vehicle, relative sliding movement between the surfaces of the plurality of wires may dampen a resonant vibration of the component.

RELATED MATTERS

This application is a continuation-in-part of U.S. patent applicationSer. No. 14/505,296 (filed Oct. 2, 2014; currently pending), which isincorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates generally to vehicle brake componentswith increased damping capacity. More specifically, the presentdisclosure relates to brake components with cables positioned within thecomponents and methods of manufacturing such components.

BACKGROUND

Motor vehicle disc brake systems generally utilize a disc brake rotor ateach respective wheel. Each rotor, for example, generally includes twooppositely-facing annular friction surfaces which, during operation ofthe brakes, are engaged by two blocks of friction material (e.g., brakepads) that are moved towards one another into contact with the twofriction surfaces so that frictional forces occur and slow the rotationof the rotor, and hence the wheel of the vehicle.

Under light braking pressures (i.e., used to control the speed of thevehicle), brake pads may make only partial contact with the rotorsurfaces, leading to unstable frictional forces between the rotor andthe brake pads. This unstable behavior of the rotor/pad friction pairmay produce high dynamic contact forces, which can, for example, excitestrong vibration of the brake pads. Since conventional brake rotors(which are generally formed of a gray cast iron) have multiple resonantfrequencies in the audible frequency range, the vibration of the brakepads may in turn excite a resonant vibration in the brake rotor thatproduces an objectionable squeal noise during operation of the brakes.

In order to prevent squeal noise occurrence, brake components, such as,for example, brake pads and rotors, may be configured with dampers toreduce brake pad vibration and suppress rotor resonant vibration.Conventional damped pads and rotors may include, for example, damperswhich utilize friction damping (i.e., Coulomb damping) from contactpressure between two surfaces that have whole-body motion relative toone another (i.e., full slip can develop between the surfaces). Suchdampers may include, for example, solid inserts and damper rings, whichcreate contact pressure between a surface of the insert/ring and asurface of the pad/rotor or a filler material within the pad/rotor.

Although such damped rotor/pad designs provide some vibrationsuppression, the damper effectiveness of such designs varies with braketemperature. The full slip condition between the sliding surfaces ofsuch components changes with brake temperature, for example, which mayresult in a change in contact pressure between the surfaces and aresulting change in damper effectiveness (i.e., a decrease in dampereffectiveness). Since the operating temperature range for a conventionalbrake component is very wide (e.g., from about −40° C. after anovernight in a cold climate during the winter to about 500° C. during anemergency stop from high speed or during a continuous use of the brakeswhile driving in a mountainous area), the friction damper effectivenessof such designs is also widely variable, and may not prevent squealnoise during certain temperature conditions.

It may, therefore, be advantageous to provide a brake component (e.g., abrake rotor and/or brake pad) with an improved damping capacity thatcontinuously prevents brake squeal noise. It may also be advantageous toprovide a brake component having an invariable damper effectiveness thatis unaffected by brake temperature changes.

SUMMARY

In accordance with various exemplary embodiments, a brake component fora motor vehicle may include a body and at least one sheathed cablepositioned within the body. The at least one sheathed cable may includea plurality of wires, each of the plurality of wires having a surface insliding contact with a surface of at least one adjacent wire of theplurality of wires. During braking of the motor vehicle, relativesliding movement between the surfaces of the plurality of wires maydampen a resonant vibration of the component.

In accordance with various additional exemplary embodiments, a brakerotor may include a cheek portion and at least one sheathed cablepositioned within the cheek portion. The at least one sheathed cable mayinclude a plurality of wires, each of the plurality of wires having asurface in sliding contact with at least one surface of an adjacent wireof the plurality of wires. During braking of the motor vehicle, slidingmovement between the surfaces of the plurality of wires may dampen aresonant vibration of the rotor.

In accordance with various further exemplary embodiments, a method ofmanufacturing a brake component may include encapsulating a cable withina sheath. The cable may include a plurality of wires in sliding contactwith one another. The method may further include positioning thesheathed cable within the brake component. The sheathed cable may bepositioned within the brake component so that, during braking of themotor vehicle, the sheathed cable is configured to dampen a resonantvibration of the brake component via friction generated by slidingmovement between the plurality of wires.

Additional objects and advantages of the disclosure will be set forth inpart in the description which follows, and in part will be obvious fromthe description, or may be learned by practice of the disclosure. Theobjects and advantages of the disclosure will be realized and attainedby means of the elements and combinations particularly pointed out inthe appended claims.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory onlyand are not restrictive of the disclosure, as claimed.

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the disclosure andtogether with the description, serve to explain the principles of thedisclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

At least some features and advantages will be apparent from thefollowing detailed description of embodiments consistent therewith,which description should be considered with reference to theaccompanying drawings, wherein:

FIG. 1 is a perspective view of an exemplary embodiment of a dampedbrake rotor in accordance with the present disclosure;

FIG. 2 is a top view of the brake rotor of FIG. 1, with a portionremoved to show a cable insert;

FIG. 3 is a top view of the cable insert of the brake rotor of FIG. 1;

FIG. 4 is a side view of the brake rotor of FIG. 1;

FIG. 5 is a cross-sectional view of the brake rotor of FIG. 1 takenthrough line 5-5 of FIG. 4;

FIG. 6 is an enlarged, partial cross-sectional view of the brake rotorof FIG. 1;

FIG. 7 shows a detailed view of a cable of the cable insert of the brakerotor of FIG. 1;

FIG. 8 is a perspective view of an exemplary embodiment of a mold inaccordance with the present disclosure for casting the brake rotor ofFIG. 1;

FIG. 9 is a top view of another exemplary embodiment of a damped brakerotor in accordance with the present disclosure, with a portion removedto show a cable insert;

FIG. 10 is a top view of the cable insert of the brake rotor of FIG. 9;

FIG. 11 is a top view of yet another exemplary embodiment of a dampedbrake rotor in accordance with the present disclosure, with a portionremoved to show a cable insert;

FIG. 12 is a top view of the cable insert of the brake rotor of FIG. 11;

FIG. 13 is a top view of yet another exemplary embodiment of a dampedbrake rotor in accordance with the present disclosure, with a portionremoved to show a cable insert;

FIG. 14 is a top view of the cable insert of the brake rotor of FIG. 13;

FIG. 15 is an enlarged, partial cross-sectional view of yet anotherexemplary embodiment of a damped brake rotor in accordance with thepresent disclosure;

FIG. 16 is a perspective view of a cable insert of the brake rotor ofFIG. 15;

FIG. 17 is an enlarged, partial cross-sectional view of yet anotherexemplary embodiment of a damped brake rotor in accordance with thepresent disclosure;

FIG. 18 is an enlarged, partial cross-sectional view of yet anotherexemplary embodiment of a damped brake rotor in accordance with thepresent disclosure;

FIG. 19 is an enlarged, partial cross-sectional view of yet anotherexemplary embodiment of a damped brake rotor in accordance with thepresent disclosure;

FIG. 20 is a perspective view of an exemplary embodiment of a dampedbrake pad in accordance with the present disclosure, with portions cutaway to show the different layers of the brake pad;

FIG. 21 is a perspective view of an exemplary embodiment of a dampedcaliper assembly in accordance with the present disclosure, which showscables embedded within a caliper and a caliper anchor bracket of theassembly;

FIG. 22 is a perspective view of the caliper of the assembly of FIG. 21;

FIG. 23 is a perspective view of a cable insert of the caliper of FIG.22;

FIG. 24 is a perspective view of the caliper anchor bracket of theassembly of FIG. 21;

FIG. 25 is a perspective view of a cable insert of the caliper anchorbracket of FIG. 24;

FIG. 26 is a perspective view of an exemplary embodiment of a steeringknuckle in accordance with the present disclosure; and

FIG. 27 is a perspective view of a cable insert of the steering knuckleof FIG. 26.

Although the following detailed description makes reference toillustrative embodiments, many alternatives, modifications, andvariations thereof will be apparent to those skilled in the art.Accordingly, it is intended that the claimed subject matter be viewedbroadly.

DESCRIPTION OF THE EMBODIMENTS

Reference will now be made in detail to various embodiments, examples ofwhich are illustrated in the accompanying drawings. The variousexemplary embodiments are not intended to limit the disclosure. To thecontrary, the disclosure is intended to cover alternatives,modifications, and equivalents.

The present disclosure contemplates brake components which utilizecables positioned (e.g., embedded) within the components to improve thedamping capacity of the components. For instance, as disclosed in U.S.patent application Ser. No. 14/505,296, which is incorporated herein byreference, in accordance with various exemplary embodiments, theexemplary embodiments described herein utilize friction created byrelative movement (e.g., sliding) between individual wires of theembedded cable (i.e., Coulomb friction) to dampen a resonant vibrationof the component. The exemplary embodiments described herein furthercontemplate encapsulating the embedded cable within a sheath configuredto prevent infiltration of molten casting material into the cable duringcasting of the brake component, thus shielding the individual wires ofthe embedded cable from the molten material and allowing them to remainfree to move relative to one another. Various exemplary embodimentsdescribed herein, for example, contemplate a brake component thatincludes at least one cable positioned within a body of the componentand a sheath encapsulating the at least one cable. The at least onecable includes a plurality of wires positioned relative to one another,each of the plurality of wires having a surface in sliding contact withat least one surface of at least one adjacent wire of the plurality ofwires, such that sliding movement of the surfaces relative to eachother, which is generated during braking of the vehicle, may dampen aresonant vibration of the component. In other words, during braking ofthe motor vehicle, the at least one cable may dampen the resonantvibration of the component via Coulomb friction generated by the slidingmovement between the surfaces of the individual wires contained withinthe cable (i.e., via interwire friction). Additionally, contact pressurebetween an outer surface of the cable and an inner surface of the sheathmay also dampen the resonant vibration of the component via slidingmovement of the surfaces relative to each (i.e., via dry friction).

As would be understood by those of ordinary skill in the art, as usedherein, the terms “sliding contact” and “sliding movement” refer tomovement between respective contact surfaces under certain conditions,such as, for example, during the breaking of a motor vehicle. In thismanner, such surfaces are slidable relative to one another only undercertain conditions, and are not always moving relative to one another.

Furthermore, due to its flexible structure, the at least one cable mayundergo relatively large elastic distortions without any noticeablechange in contact pressure between the individual wires of the cable.Thus, brake components in accordance with the present disclosure (whichrely on a “static” interwire friction force to dampen undesired brakesqueal noise) are also relatively impervious to brake temperaturechanges.

As understood by those of ordinary skill in the art, Coulomb friction isa simplified quantification of the friction force that exists betweentwo dry surfaces in contact with each other. Accordingly, as would alsobe understood by those of ordinary skill in the art, Coulomb frictiondamping, as utilized herein, is the effect of the friction force todissipate energy from a vibrating component and/or system. In otherwords, Coulomb friction damping refers to a type of constant mechanicaldamping in which energy is absorbed via sliding friction. For example,in accordance with the present disclosure, kinetic energy from avibrating brake component is converted into thermal energy or heat bythe sliding friction.

FIGS. 1-7 illustrate an exemplary embodiment of a damped brake rotor 100in accordance with the present disclosure. The brake rotor 100 includesa body 101, at least one cable 108 (e.g. two cables 108 being shown inthe exemplary brake rotor 100 in FIGS. 5-7) positioned within the body101, and a sheath 110 encapsulating the at least one cable 108 (e.g.,two sheaths 110 being shown in the exemplary brake rotor 100, such thateach cable 108 is encapsulated by a respective sheath 110). As explainedin more detail below, various embodiments of the present disclosure,contemplate encapsulating the cables 108 within the sheaths 110 toshield the cables 108 from molten casting material during the rotorcasting process.

The body 101 includes a solid cheek portion 102 and a mounting surface104. In various exemplary embodiments, the mounting surface 104 extendsfrom the cheek portion 102 to connect the brake rotor 100 to a wheel(not shown) of a motor vehicle (not shown) via, for example, a steeringknuckle 700 (see FIG. 31).

In various exemplary embodiments, the sheathed cables 108 are embeddedwithin the solid cheek portion 102. As explained in more detail below,various embodiments of the present disclosure, contemplate embedding thesheathed cables 108 within the cheek portion 102 during the rotorcasting process such that the sheathed cables 108 are centrallypositioned within the cheek portion 102. In various exemplaryembodiments, and perhaps as best shown in FIGS. 2 and 3, the sheathedcables 108 (i.e., the cables 108 being encapsulated within the sheaths110) are configured as an insert 107 that is embedded within the cheekportion 102. The insert 107 may, for example, include at least onelocator feature 109 (e.g., seven locator features 109 being shown in theexemplary brake rotor 100), which is configured to both hold the cables108 together and maintain the shape of each cable 108 (and the overallshape of the insert 107). As also explained below, in various additionalembodiments, the at least one locator feature 109 also is used duringthe rotor casting process to locate the insert 107 within a casting mold120 (see FIG. 8)). In this manner, the cables 108 may be properlypositioned and aligned within the cheek portion 102 (of the cast rotor100) to maximize their damping capacity.

As above, the insert 107 may, for example, be relatively centrallypositioned within the cheek portion 102 to prevent exposure of thesheathed cables 108 if the rotor 100 begins to degrade (i.e., if thecheek portion 102 starts wearing down). In various embodiments, forexample, in which the cheek portion 102 has a thickness t of about 12mm, each sheathed cable 108 may be positioned such that an outer surfaceof the sheathed cable 108 is at least about 3 mm from an outer surfaceof the rotor 100. In other words, each sheathed cable 108 may bepositioned such that there is a distance D_(R) of at least about 3 mmbetween the sheathed cable 108 and an outer surface of the cheek portion102 (see FIG. 6).

As best shown perhaps in the enlarged view of FIG. 7, each cable 108includes a plurality of wires 114. In various embodiments, for example,each cable 108 has a diameter d_(c) of about 3 mm to about 6 mm, andincludes about 7 to about 60 wires 114. Those of ordinary skill in theart would understand, however, that the cable 108 illustrated in FIG. 7is exemplary only and intended to illustrate one embodiment of thepresent disclosure. The present disclosure, therefore, contemplatescables 108 having any number, type, and/or configuration (i.e.,dimension and/or geometry) of wires 114, based on a particularapplication. In accordance with various embodiments, for example, thewires 114 may form a helical, parallel-wire, or locked-coil strand cable108, as understood by those of ordinary skill. Those of ordinary skillin the art would further understand that the wires 114 (i.e., formingeach cable 108) may each have the same diameter (e.g., d_(w) asillustrated in FIG. 7), or may have differing diameters.

As shown best perhaps in FIGS. 6 and 7, as above, a respective sheath110 fully encapsulates each of the cables 110 to prevent the moltencasting material used to form the rotor 100 from infiltrating the cables108 and interfering with the wires 114 of each cable 108. With referenceto FIG. 7, for example, the wires 114 of each cable 108, therefore,remain in contact with one another such that a state of Coulomb frictionexists between the wires 114. In other words, the individual wires 114of each cable 108 remain free to move with respect to one another, andrespective surfaces 116 of the wires 114 are in contact with each othersuch that a friction force (Coulomb friction) exists between eachrespective pair of contacting surfaces 116 of the wires 114 (i.e.creating interwire friction). During braking of the motor vehicle, thecables 108 may, therefore, dampen a resonant vibration of the rotor 100via the Coulomb friction between the wires 114, which works to absorbthe kinetic energy of the rotor 100 (i.e., produced from the vibrationof the rotor 100) and convert it into thermal energy. As would beunderstood by those of ordinary skill in the art, the damping capacityof each cable 108 is a function of the total surface contact area of theindividual wires 114 forming the cable 108. Accordingly, the larger thesurface contact area between the wires 114, the higher the dampingcapacity of the cable 108. In this manner, the size, density, andspacing of the wires 114 may be chosen based on a desired dampingcapacity of the cables 108.

Furthermore, each cable 108 also remains free to move with respect tothe sheath 110 in which it is encapsulated, such that an outer surface119 of the cable 108 and an inner surface 121 of the sheath 110 are incontact with each other such that a friction force also exists betweenthe contacting surfaces 119 and 121 (i.e. creating a dry friction).During braking of the motor vehicle, this contact pressure (i.e.,between surfaces 119 and 121) may also dampen the resonant vibration ofthe component.

In accordance with various exemplary embodiments, each sheath 110 ismade of a shield material 112, such as, for example, a metal alloy thathas a higher melting point then the molten casting material used to formthe rotor 100. In various embodiments, for example, the sheaths 110 maybe formed from a steel-based alloy, such as, for example, plain carbonsteel alloys (e.g., 1040 or 1241 or 1520), low alloy steels (e.g., 4120,4325, 8339, or 8610), and/or stainless steel alloys (e.g., 202, 304,316, 409, or 430) having a melting point ranging from about 1353° C. toabout 1530° C. And, the rotor 100 may be cast with a cast iron having amelting point ranging from about 1120° C. to about 1250° C. Accordingly,this difference in melting temperatures (i.e., between the alloy andcast iron), in combination with the fact that the cast iron is beginningto cool when it comes into contact with the sheaths 110, prevents thesheaths 110 from melting and allows the sheaths 110 to shield the cables108 from the cast iron.

As discussed further below, in accordance with various embodiments, eachsheath 110 is formed by wrapping a sheet of the shield material 112around a respective cable 108, such that the shield material 112 fullyencapsulates the cable 108. Thus, various embodiments of the presentdisclosure contemplate using a ductile metal alloy as the shieldmaterial 112, such that the shield material 112 can be rolled into athin sheet and wrapped around a circumference of the cable 108 to formthe sheath 110. In various embodiments, for example, each sheath 110 mayhave a thickness, t_(s), of greater than or equal to about 0.005 inches(0.127 mm). Those of ordinary skill in the art would understand,however, that the thickness, t_(s), of each sheath 110 is a function ofthe specific metal alloy used to form the sheath 110; and that, ingeneral, the higher the melting point of the metal alloy, the thinnerthe sheath can be. Furthermore, a maximum thickness of the sheath 110 isonly limited by the ductility of the metal alloy that is used and thediameter d_(c) of the cable 108 to be wrapped.

The present disclosure contemplates securing opposite ends 111, 113 ofthe shield material 112 to form the sheath 110 using various methods andtechniques known to those of ordinary skill in the art. As illustratedbest perhaps in FIG. 7, in various exemplary embodiments, the shieldmaterial 112 is wrapped around the circumference of the cable 108 suchthat the opposite ends 111, 113 of the shield material 112 form anoverlap 115. Various additional exemplary embodiments contemplateproviding an overlap that is large enough to substantially prevent themolten casting material from infiltrating an area 117 between theopposite ends 111, 113 of the shield material 112. In variousembodiments, for example, the overlap 115 spans at least about 25% ofthe circumference of the cable 108. In various additional exemplaryembodiments, the opposite ends 111, 113 of the shield material 112 aresecured via welding, clinching, and/or cramping the ends 111, 113together. In such embodiments, the ends 111, 113 may be directly affixedto each other without providing an overlap 115.

Thus, each respective sheath 110 may shield the wires 114 of the cable108 encapsulated within the sheath 110 from the casting iron used tocast the rotor 110. Thus, the outer surface of each sheath 110 will berigidly bonded to the casting iron of the rotor 100 during the rotorcasting process, while allowing the individual wires 114 of each cable108 to remain unbonded and free to move with respect to one another. Inthis manner, the insert 107 is held firmly in place within the rotorcheek 102, and prevents relative whole-body motion between internalsurfaces of the rotor cheek 102 and the outer surface of the sheaths 110(i.e., preventing full slip from developing between the surfaces of therotor 100 and the sheaths 110). This bonding may additionally help tomaintain the structural integrity of the rotor 100, which couldotherwise be comprised due to the embedded cable 108.

Those of ordinary skill in the art would understand, however, that thesheaths 110 illustrated in FIGS. 6 and 7 are exemplary only and intendedto illustrate one embodiment of the present disclosure. Accordingly,sheaths in accordance with the present disclosure may be formed ofvarious materials with various properties (such as aluminum alloys,including, for example, 1100, 2124, 3003, 5452, 6061, and/or 7075), havevarious configurations utilizing various commercially-availablefastening techniques, and be formed of various layers of shield material(i.e., the shield material 112 may be wrapped multiple times around thecircumference of the cable 108 to achieve a desired thickness t_(s) ofthe sheath 110), without departing from the present scope of thedisclosure and claims. Those of ordinary skill in the art would alsounderstand that the disclosed sheaths 110 may be pre-formed, such that arespective cable 108 may be inserted into each sheath 110 (as opposed toa shield material 112 being wrapped around each cable 108 to form eachsheath 110).

In accordance with various exemplary embodiments, the at least one cable108 may be shaped and/or configured to provide a specific pattern, orspatial distribution of damping capacity, across the cheek portion 102to increase damping capacity most in the areas of the cheek 102 thathave the highest vibration amplitudes during rotor resonances. Thus, asillustrated in FIGS. 1-7, in various embodiments, for example, thesheathed cables 108 may form a series of circular rings, which increasethe damping capacity of the solid rotor cheek portion 102. The presentdisclosure, however, contemplates brake rotors including any number,configuration (i.e., dimension and/or geometry), shape (i.e., pattern),and/or orientation of cables 108, having any number and/or configurationof wires 114, based on a particular application. Those of ordinary skillin the art would understand, therefore, that the brake rotor 100illustrated in FIGS. 1-7 is exemplary only and intended to illustrateone embodiment of the present disclosure. Accordingly, damped brakerotors in accordance with the present disclosure may have variousconfigurations and/or orientations of cheeks and sheathed cables (e.g.,inserts) positioned within, without departing from the scope of thepresent disclosure and claims, and are not bound by any specificgeometries and/or orientations.

Thus, in accordance with various embodiments of the present disclosure,a damped brake rotor may include inserts having various numbers ofsheathed cables forming various patterns (i.e., having various spatialdistributions). As illustrated in FIGS. 9-12, in various embodiments,for example, a damped brake rotor 150, 160 may respectively include aninsert 157, 167 having a sheathed cable (wherein only a sheath 151, 161is shown) forming a wave pattern (e.g., a sine wave, wherein a period ofa wave formed by the sheathed cable in FIGS. 9 and 10 is larger than aperiod of a waved formed by the sheathed cable in FIGS. 11 and 12). And,in various additional embodiments, a damped brake rotor 170 may includean insert 177 having sheathed cables (wherein only a sheath 171 isshown) forming a pattern that combines circular rings with a wavepattern (e.g. a sine wave), as illustrated in FIGS. 13 and 14. Similarto the above insert 107 of the rotor 100, each of the inserts 157, 167,177 may also respectively include at least one locator feature 159, 169,179 that is used, for example, to locate the insert 159, 169, 179 withina casting mold during the rotor casting process.

In accordance with various additional embodiments of the presentdisclosure, a damped brake rotor may have a vented cheek portion. FIGS.15-19 illustrate, for example, an exemplary embodiment of a damped,ventilated brake rotor 200 in accordance with the present disclosure.The brake rotor 200 includes a cheek portion 202 having an outerfriction member 203 that is connected to an inner friction member 205 bya plurality of fin elements 206. The brake rotor 200, for example,further includes a mounting surface 204 that extends from the innerfriction member 205 to connect the brake rotor 200 to a wheel (notshown) of a motor vehicle (not shown). In this manner, the outerfriction member 203 is configured to face away from the vehicle when therotor 200 is attached to the wheel, and the inner friction member 205 isconfigured to face towards the vehicle when the rotor 200 is attached tothe wheel.

Similar to the brake rotor 100, the brake rotor 200 includes at leastone cable 208 (e.g., four cables 208 being shown in the exemplary brakerotor 200) embedded within the cheek portion 202 and a sheath 210encapsulating each of the cables 208. Each cable 208 includes aplurality of wires 214 in contact with one another such that a state ofCoulomb friction exists between the wires 214. As above, variousembodiments of the present disclosure, contemplate embedding thesheathed cables 208 within the cheek portion 202 during the rotorcasting process, wherein the sheaths 210 are configured to prevent themolten casting material from infiltrating the cables 208 and interferingwith the wires 214 of each cable 208. In various exemplary embodiments,the sheathed cables 208 are embedded within one or both of the outer andinner friction members 203 and 205. As illustrated in FIGS. 15 and 16,for example, in various embodiments, the sheathed cables 208 areconfigured as inserts 207 that are embedded in each of the outer andinner friction members 203 and 205. Each insert 207 may, for example,include at least one locator feature 209 (e.g., seven locator features209 being shown on each exemplary insert 207), which, as above, isconfigured to hold the sheathed cables 208 together, maintain the shapeof each sheathed cable 208 (and the overall shape of each insert 207),and to locate each insert 207 within the casting mold. Thus, as above,the sheathed cables 208 may be properly positioned and aligned withineach respective friction member 203, 205 (of the cast rotor 200) tomaximize their damping capacity.

Similar to the insert 107, each insert 207 may, for example, berelatively centrally positioned within each respective friction member203, 205 to prevent exposure of the sheathed cables 208 if the rotor 200begins to degrade (i.e., if the cheek portion 202 starts wearing down).In various embodiments, for example, in which each friction member 203,205 has a thickness T of about 7 mm to about 13 mm, each sheathed cable208 may be positioned such that an outer surface of the sheathed cable208 is at least about 3 mm from an outer face of the rotor 200 and atleast about 5 mm from a peripheral edge of the rotor 200. In otherwords, each sheathed cable 208 may be positioned such that there is adistance D_(f) of at least about 3 mm between the cable 208 and an outerface of the cheek portion 202 and a distance D_(p) of at least about 5mm between the cable 208 and a peripheral edge of the cheek portion 202.(see FIG. 15).

As above, the sheathed cables 208 may be shaped and/or configured toprovide a specific pattern, or spatial distribution of damping capacity,across the cheek portion 202 to increase damping capacity most in theareas of the cheek 202 that have the highest vibration amplitudes duringrotor resonances. As illustrated in FIGS. 15 and 16, in variousembodiments, for example, the sheathed cables 208 may form a series ofcircular rings, which increase the damping capacity of each of the outerand inner friction members 203 and 205. Also as above, however, thepresent disclosure contemplates ventilated brake rotors including anynumber, configuration (i.e., dimension and/or geometry), shape (i.e.,pattern), and/or orientation of cables 208 encapsulated within sheaths210, having any number and/or configuration of wires 214.

Those of ordinary skill in the art would understand, therefore, that theventilated brake rotor 200 illustrated in FIGS. 15 and 16 is exemplaryonly and intended to illustrate one embodiment of the presentdisclosure. Accordingly, damped, ventilated brake rotors in accordancewith the present disclosure may have various configurations and/ororientations of friction members and cables (e.g., inserts) positionedwithin, without departing from the scope of the present disclosure andclaims, and are not bound by any specific geometries and/ororientations. Furthermore, the outer fiction member 203 may have adifferent insert configuration than the inner friction member 205 (seeFIG. 17). As illustrated in FIGS. 17-19, in various embodiments, forexample, a damped, ventilated brake rotor 250, 260, 270 may respectivelyinclude inserts 257, 267, 277 having cables 258, 268, 278, which areencapsulated in sheaths 251, 261, 271, arranged in variousconfigurations, and having various diameters.

Those of ordinary skill in the art would further understand that thebrake rotors 100, 200, 250, 260, 270 illustrated in FIGS. 1-19 areexemplary only and intended to illustrate one type of brake componentcontemplated by the present disclosure. As disclosed in U.S. patentapplication Ser. No. 14/505,296, which is incorporated herein byreference, the present disclosure contemplates various additional typesand configurations of brake components, which utilize cables positionedwithin the components to improve the damping capacity of the components.Furthermore, similar to the brake rotors disclosed above, the presentdisclosure also contemplates encapsulating such cables within sheaths toprevent molten casting material from infiltrating the cables during thecasting process of the components.

Various additional embodiments of the present disclosure contemplate,for example, brake pads, which utilize Coulomb friction betweenindividual wires of a cable positioned within the pad to dampen aresonant vibration of the pad. Similar to the above disclosed rotors,the brake pads also include a sheath encapsulating the cable. FIG. 20,for example, illustrates an exemplary embodiment of a damped brake padassembly 300 in accordance with the present disclosure. The brake pad300 includes a rigid backing structure, such as, for example, a metallicbacking plate 302, and a friction material 304 that is carried by thebacking plate 302. The friction material 304 is made, for example, froma material and/or combination of materials which have a high coefficientof friction and which may also absorb and disperse large amounts heat.In various embodiments, for example, the friction material 304 mayinclude a non-asbestos organic, semi-metallic, and/or ceramic material.

Those of ordinary skill in the art would understand, however, that brakepads in accordance with the present disclosure may include various typesand/or configurations of backing structures and friction materials,which are formed from various materials, based on a particular brakingapplication. Furthermore, brake pads in accordance with the presentdisclosure may include additional components and/or materials,including, for example, an underlayer material 306 that is positionedbetween the backing plate 302 and the friction material 304 and a shim307 attached to an outer surface of the backing plate 302 to helpcorrect small differences (which may sometimes lead to noise) betweenthe backing plate 302 and a caliper to which it is attached.

In various exemplary embodiments, the friction material 304 is bound toa surface of the backing plate 302 to create a friction surface that isconfigured to face a brake rotor when positioned within the motorvehicle (not shown), and the shim 307 is bound to an opposite surface ofthe backing plate 302 (which is configured to be attached to a caliper(see FIG. 22) when positioned within the vehicle). In variousembodiments, for example, two brake pads 300 may be contained within thebrake caliper (i.e., positioned over a cheek portion of the rotor) withtheir friction surfaces facing the rotor. In this manner, when thebrakes are applied, the caliper clamps or squeezes the two pads 300together onto the spinning rotor to slow and/or stop the vehicle.

Similar to the above damped brake rotors, in accordance with variousexemplary embodiments, the brake pad assembly 300 also includes at leastone cable 308 (e.g., one cable 308 being shown in the exemplary brakepad 300) positioned within the brake pad 300, and a sheath 310encapsulating the cable 308. In various embodiments, for example, thecable 308 may be positioned within the backing plate 302, and the sheath310 may prevent molten casting material from infiltrating the cable 308during the casting of the backing plate 302.

Similar to the cables 108 above, the cable 308 includes a plurality ofwires (not shown). In various embodiments, for example, the cable 308has a diameter of about 1 mm to about 3 mm, and includes about 3 toabout 20 wires, each having a diameter of about 0.1 mm to about 1.4 mm.Also as above, the wires of the cable 308 are in contact with oneanother such that a state of Coulomb friction exists between the wires.Thus, similar to the cables 108, during braking of the motor vehicle,the cable 308 may dampen a resonant vibration of the brake pad 300 viathe Coulomb friction between the contacting surfaces of the wires, whichworks to absorb the kinetic energy of the brake pad 300 and convert itinto thermal energy.

Similar to the above cables 108, the at least one cable 308 may beshaped and/or configured to provide a specific pattern, or spatialdistribution of damping capacity, across the backing plate 302 toincrease damping capacity most in the areas of the backing plate 302that have the highest vibration amplitudes during brake pad resonances.In various embodiments, for example, the sheathed cable 308 may form awave pattern (e.g. a sine wave), which increases the damping capacity ofthe brake pad 300. The present disclosure, however, contemplates brakepads including any number, configuration (i.e., dimension and/orgeometry), shape (i.e., pattern), and/or orientation of cables 308,having any number and/or configuration of wires. Those of ordinary skillin the art would understand, therefore, that the brake pad 300illustrated in FIG. 20 is exemplary only and intended to illustrate oneembodiment of the present disclosure.

Accordingly, damped brake pads in accordance with the present disclosuremay have various configurations and/or orientations of backing platesand sheathed cables positioned within, without departing from the scopeof the present disclosure and claims, and are not bound by any specificgeometries and/or orientations.

Various additional embodiments of the present disclosure contemplate,caliper assemblies, including a caliper and a caliper anchor bracket,which utilize Coulomb friction between individual wires of cablespositioned within the assembly to dampen a resonant vibration of theassembly (i.e., of the caliper and/or anchor bracket). Similar to theabove disclosed rotors and brake pads, caliper assemblies also includesheaths encapsulating the cables. FIGS. 21-25 illustrate an exemplaryembodiment of a damped caliper assembly 400 in accordance with thepresent disclosure. As shown in FIG. 21, the caliper assembly 400includes a caliper 500 and a caliper anchor bracket 600 that isconfigured to mount a brake pad to the caliper 500. As above, in variousexemplary embodiments, two brake pads may be contained within thecaliper 500 (i.e., which is positioned over a cheek portion of a rotor)with their friction surfaces facing the rotor. In this manner, when thebrakes are applied, the caliper 500 clamps or squeezes the two padstogether onto the spinning rotor to slow and/or stop the vehicle.

Similar to the above damped brake rotors and brake pads, in accordancewith various exemplary embodiments; the caliper assembly 400 alsoincludes at least one cable positioned within the assembly 400 and asheath encapsulating the at least one cable. In various embodiments, forexample, a sheathed cable (wherein only a sheath 510 is visible) may beembedded within the caliper 500 as shown in FIG. 23. In variousadditional embodiments, a sheathed cable (wherein only a sheath 610 isvisible) may be embedded within the anchor bracket 600 as illustrated inFIG. 25. Similar to the above brake rotor 100, various embodiments ofthe present disclosure, contemplate embedding the respective sheathedcables within the caliper 500 and anchor bracket 600 during the castingprocess such that the cables are positioned to maximize each componentsrespective damping capacity. Furthermore, embodiments of the presentdisclosure contemplate that the sheaths 510, 610 will shield therespective cables from the molten casting material used to cast thecomponents during the casting process.

As shown respectively in FIGS. 23 and 25, in various embodiments, thesheathed cables are configured as inserts 507, 607 that are respectivelyembedded within the caliper 500 and anchor bracket 600. Similar to theinsert 107 above, each insert 507, 508 may, for example, respectivelyinclude at least one locator feature 509, 609 (e.g., three locatorfeatures 509, 609 being shown in the exemplary caliper 500 and anchorbracket 600), which are used during the casting process to locate eachinsert 507, 607 within a casting mold. In this manner, the sheathedcables may each be properly positioned and aligned within the caliper500 and anchor bracket 600 to maximize each component's respectivedamping capacity.

Similar to the cables 108 and 308 above, the cables within sheaths 510,610 each include a plurality of wires (not shown) that are in contactwith one another such that a state of Coulomb friction exists betweenthe contacting surfaces of the wires. Thus, similar to the cables 108,308, during braking of the motor vehicle, the cables may respectivelydampen a resonant vibration of the caliper 500 and the anchor bracket600 (and the overall resonant vibration of the caliper assembly 400) viathe Coulomb friction between the wires, which works to absorb thekinetic energy of the caliper assembly 400 and convert it into thermalenergy.

Those of ordinary skill in the art would understand, however, that thecaliper assembly 400, including the caliper 500 and the anchor bracket600, illustrated in FIGS. 21-25 is exemplary only and intended toillustrate one embodiment of the present disclosure. Accordingly,caliper assemblies in accordance with the present disclosure may havevarious configurations, including various configurations of calipers andanchor brackets, without departing from the scope of the presentdisclosure and claims, and are not bound by any specific designs,geometries and/or orientations.

Those of ordinary skill in the art would further understand that thepresent disclosure contemplates caliper assemblies 400, including anynumber, configuration (i.e., dimension and/or geometry), shape (i.e.,pattern), and/or orientation of sheathed cables, having any numberand/or configuration of wires, embedded within the caliper 500 and/orthe anchor bracket 600.

Various further embodiments of the present disclosure contemplatesteering knuckles which utilize Coulomb friction between individualwires of cables positioned within the knuckle to dampen a resonantvibration of the knuckle. Similar to the above disclosed rotors, brakepads, and caliper assemblies, the disclosed steering knuckles alsoinclude sheaths encapsulating the cables. FIGS. 26 and 27 illustrate anexemplary embodiment of a damped steering knuckle 700 in accordance withthe present disclosure. In various embodiments, for example, a wheel andtire assembly of a motor vehicle (not shown) may be attached to thevehicle's suspension via the knuckle 700 (i.e., the knuckle 700 mayallow the tire/wheel to rotate while being held in a stable plane ofmotion).

Similar to the above brake components, in accordance with variousexemplary embodiments, the knuckle 700 includes at least one cableembedded within the knuckle 700 and a sheath 710 encapsulating the atleast one cable. As shown in FIG. 27, in various embodiments, thesheathed cable (wherein only a sheath 710 is visible) is configured asan insert 707 that is embedded within the knuckle 700. The insert 707may, for example, include at least one locator feature 709 (e.g., threelocator features 709 being shown in the exemplary knuckle 700), which isused during the casting process to locate the insert within a castingmold.

Similar to the cables discussed above, the cable within sheath 710includes a plurality of wires (not shown) that are in contact with oneanother such that a state of Coulomb friction exists between thecontacting surfaces of the wires. Thus, during braking of the motorvehicle, the cable may dampen a resonant vibration of the knuckle 700via the Coulomb friction between the wires.

As further disclosed in U.S. patent application Ser. No. 14/505,296,which is incorporated herein by reference, the present disclosure alsocontemplates methods of manufacturing a brake component, such as, forexample, the components 100, 150, 160, 170, 200, 250, 260, 270, 300,400, 500, 600, and 700 described above with reference to FIGS. 1-27 inorder to increase the damping capacity of the component. In accordancewith various exemplary embodiments, to increase the damping capacity ofthe brake component 100, 150, 160, 170, 200, 250, 260, 270, 300, 400,500, 600, 700, a cable 108, 208, 258, 268, 278, 308 may be positionedwithin the brake component 100, 150, 160, 170, 200, 250, 260, 270, 300,400, 500, 600, 700. To protect the cable 108, 208, 258, 268, 278, 308from the molten casting material used during the manufacturing of thebrake component 100, 150, 160, 170, 200, 250, 260, 270, 300, 400, 500,600, 700, the present disclosure further contemplates encapsulating thecable 108, 208, 258, 268, 278, 308 within a sheath 110, 151, 161, 171,210, 251, 261, 271, 310,410, 510, 610, 710.

In various embodiments, for example, the cable 108, 208, 258, 268, 278,308, may include a plurality of wires in sliding contact with oneanother and the sheath 110, 151, 161, 171, 210, 251, 261, 271, 310,410,510, 610, 710 is configured to shield the cable 108, 208, 258, 268, 278,308 from molten casting material and prevent the molten casting materialfrom interfering with the sliding contact between the plurality ofwires. In this manner, the sheathed cable 108, 208, 258, 268, 278, 308,may be positioned within the brake component 100, 150, 160, 170, 200,250, 260, 270, 300, 400, 500, 600, 700 so that, during braking of themotor vehicle, the at least one cable 108, 208, 258, 268, 278, 308,dampens a resonant vibration of the component 100, 150, 160, 170, 200,250, 260, 270, 300, 400, 500, 600, 700 via friction generated by slidingmovement between the plurality of wires.

The brake components 100, 150, 160, 170, 200, 250, 260, 270, 300, 400,500, 600, 700 may be manufactured using any known methods and/ortechniques known to those of ordinary skill in the art. In variousembodiments, for example, the components 100, 150, 160, 170, 200, 250,260, 270, 300 (e.g., the backing plate 302), 400, 500, 600, 700 may becast from a molten metal, such as, for example, iron that is poured intoa mold. In various additional embodiments, the components may be moldedfrom a composited material, such as, for example, reinforcedcarbon-carbon, a ceramic matrix composite, or a composite blend ofmaterials with a Phenolic plastic resin that is hot molded in a curingpress.

With reference to the brake rotor 100 described above and illustrated inFIGS. 1-8, for example, in accordance with various exemplaryembodiments, a plurality of cables 108 may be encapsulated withinrespective sheaths 110. In various embodiments, for example, each sheath110 is formed by wrapping a sheet of the shield material 112 around arespective cable 108, such that the shield material 112 fullyencapsulates the cable 108. Thus, as above, various embodiments of thepresent disclosure contemplate using a ductile metal alloy, such as, forexample, plain carbon steel alloys (e.g., 1020), low alloy steels (e.g.,4110), stainless steel alloys (e.g., 304), copper alloys (e.g., C10100),brass and bronze alloys (e.g., C60800), magnesium alloys (e.g., AM60),aluminum alloys (e.g., 1100 Al), titanium (e.g., Grade 5), tungsten,and/or other common wires (e.g., chromel, alumel, an/or constantan) asthe shield material 112, such that the shield material 112 can be rolledinto a thin sheet and wrapped around a circumference of the cable 108 toform the sheath 110.

As above, the present disclosure contemplates securing opposite ends111, 113 of the shield material 112 to form the sheath 110 using variousmethods and techniques known to those of ordinary skill in the art. Asillustrated in FIG. 7, in various exemplary embodiments, the shieldmaterial 112 is wrapped around the circumference of the cable 108 suchthat the opposite ends 111, 113 of the shield material 112 form anoverlap 115. Various additional exemplary embodiments contemplateproviding an overlap that is large enough to substantially prevent themolten casting material used during the manufacturing of the rotor 100from infiltrating an area 117 between the opposite ends 111, 113 of theshield material 112. In various embodiments, for example, the overlap115 spans at least about 25% of the circumference of the cable 108. Invarious additional exemplary embodiments, the opposite ends 111, 113 ofthe shield material 112 may be secured via welding, clinching, and/orcramping the ends 111, 113 together. In such embodiments, the ends 111,113 may be directly affixed to each other without providing an overlap115.

The plurality of sheathed cables may then be embedded within a cheekportion 102 of the rotor 100. As illustrated in FIG. 8, in variousembodiments, the sheathed cables may be configured into at least oneinsert 107 (one insert 107 being shown in the exemplary embodiment ofFIG. 8) that is placed into a casting mold 120, which is configured toform the rotor 100. In various embodiments, for example, the insert 107may be placed into the casting mold 120 by locating the insert 107between an upper pattern 130 of the casting mold 120 and a lower pattern140 of the casting mold 120.

The insert 107 may be located between the upper and lower patterns 130and 140, for example, by aligning at least one locator feature 109 (fourlocator features 109 being shown in the exemplary embodiment of FIG. 8)on the insert 107 with at least one corresponding locator feature 139,149 in each of the upper and lower patterns 130 and 140. In this manner,the cables 108 may be properly positioned and aligned within the castingmold 120.

A brake rotor 100 may then be cast with a molten casting material thatis, for example, poured into the casting mold 120, wherein the sheath110 is configured to shield the cable 108 from the molten castingmaterial and prevent the molten casting material from interfering withthe sliding contact between the plurality of wires. As above, inaccordance with various exemplary embodiments, each sheath 110 is madeof a shield material 112, such as, for example, a ductile metal alloythat has a higher melting point then the molten casting material used toform the rotor 100. In various embodiments, for example, the sheaths 110may be formed from a steel-based alloy, such as, for example, plaincarbon steel alloys (e.g., 1040 or 1241 or 1520), low alloy steels(e.g., 4120, 4325, 8339, or 8610), and/or stainless steel alloys (e.g.,202, 304, 316, 409, or 430), having a melting point ranging from about1353° C. to about 1530° C. And, the rotor 100 may be cast with a castiron having a melting point ranging from about 1120° C. to about 1250°C. Accordingly, this difference in melting temperatures (i.e., betweenthe alloy and cast iron), in combination with the fact that the castiron is beginning to cool when it comes into contact with the insert107, prevents the sheaths 110 from melting and allows the sheaths 110 toshield the cables 108 from the cast iron.

In various additional embodiments, after casting the brake rotor 100,portions of the locator features 109 that extend beyond a periphery ofthe rotor 100 (see FIG. 1) may be degated (or removed), as would beunderstood by those of ordinary skill in the art.

While the present disclosure has been disclosed in terms of exemplaryembodiments in order to facilitate better understanding of thedisclosure, it should be appreciated that the disclosure can be embodiedin various ways without departing from the principle of the disclosure.Therefore, the disclosure should be understood to include all possibleembodiments which can be embodied without departing from the principleof the disclosure set out in the appended claims. Furthermore, althoughthe present disclosure has been discussed with relation to automotivevehicles having disk brakes (i.e., utilizing rotors), those of ordinaryskill in the art would understand that the present teachings asdisclosed would work equally well for any type of vehicle having abraking system that utilizes brake rotors, as well as vehicles havingother types of braking systems, such as, for example, drum brakes (i.e.,utilizing brake drums, wherein a sheathed cable is positioned within thebody of the brake drum).

For the purposes of this specification and appended claims, unlessotherwise indicated, all numbers expressing quantities, percentages orproportions, and other numerical values used in the specification andclaims, are to be understood as being modified in all instances by theterm “about.” Accordingly, unless indicated to the contrary, thenumerical parameters set forth in the written description and claims areapproximations that may vary depending upon the desired propertiessought to be obtained by the present disclosure. At the very least, andnot as an attempt to limit the application of the doctrine ofequivalents to the scope of the claims, each numerical parameter shouldat least be construed in light of the number of reported significantdigits and by applying ordinary rounding techniques.

It is noted that, as used in this specification and the appended claims,the singular forms “a,” “an,” and “the,” include plural referents unlessexpressly and unequivocally limited to one referent. Thus, for example,reference to “a sensor” includes two or more different sensors. As usedherein, the term “include” and its grammatical variants are intended tobe non-limiting, such that recitation of items in a list is not to theexclusion of other like items that can be substituted or added to thelisted items.

It will be apparent to those skilled in the art that variousmodifications and variations can be made to the system and method of thepresent disclosure without departing from the scope its teachings. Otherembodiments of the disclosure will be apparent to those skilled in theart from consideration of the specification and practice of theteachings disclosed herein. It is intended that the specification andembodiment described herein be considered as exemplary only.

What is claimed is:
 1. A brake component, comprising: a body; and atleast one sheathed cable positioned within the body and comprising aplurality of wires, each of the plurality of wires having a surface insliding contact with a surface of at least one adjacent wire of theplurality of wires, wherein, during braking of a motor vehicle, relativesliding movement between the surfaces of the plurality of wires dampensa resonant vibration of the component.
 2. The brake component of claim1, wherein the brake component is a brake rotor.
 3. The brake componentof claim 1, wherein the brake component includes a brake pad, a caliper,a caliper anchor bracket, and/or a steering knuckle.
 4. A brake rotor,comprising: a cheek portion; and at least one sheathed cable positionedwithin the cheek portion and comprising a plurality of wires, each ofthe plurality of wires having a surface in sliding contact with at leastone surface of an adjacent wire of the plurality of wires, wherein,during braking of a motor vehicle, sliding movement between the surfacesof the plurality of wires dampens a resonant vibration of the rotor. 5.The brake rotor of claim 4, wherein the cheek portion comprises an outerfriction member and an inner friction member, and wherein the at leastone sheathed cable is positioned between the outer friction member andthe inner friction member.
 6. The brake rotor of claim 4, wherein the atleast one sheathed cable comprises a plurality of sheathed cablespositioned within the cheek portion.
 7. The brake rotor of claim 4,wherein the at least one sheathed cable forms a circular ring.
 8. Thebrake rotor of claim 4, wherein the at least one sheathed cable forms awave pattern.
 9. The brake rotor of claim 4, wherein the cheek portioncomprises an outer friction member, an inner friction member, and aplurality of fin elements connecting the outer friction member to theinner friction member, and wherein the at least one sheathed cable ispositioned within the outer friction member and/or the inner frictionmember.
 10. A method of manufacturing a brake component for a motorvehicle, comprising: encapsulating a cable within a sheath, the cablecomprising a plurality of wires in sliding contact with one another; andpositioning the sheathed cable within the brake component, wherein thesheathed cable is positioned within the brake component so that, duringbraking of the motor vehicle, the sheathed cable is configured to dampena resonant vibration of the brake component via friction generated bysliding movement between the plurality of wires.
 11. The method of claim10, wherein the encapsulating comprises wrapping the cable with a shieldmaterial to form the sheath.
 12. The method of claim 11, wherein theshield material is a metal alloy chosen from steel, aluminum, magnesium,copper, brass, bronze, titanium, or tungsten.
 13. The method of claim11, wherein wrapping the cable with the shield material compriseswrapping the shield material around a circumference of the cable suchthat opposite ends of the shield material form an overlap.
 14. Themethod of claim 13, wherein the overlap is about 25% of thecircumference of the cable.
 15. The method of claim 11, wherein wrappingthe cable with the shield material comprises wrapping the shieldmaterial around a circumference of the cable and sealing opposite endsof the shield material together.
 16. The method of claim 10, wherein thebrake component includes a brake rotor, and wherein the positioningcomprises placing an insert including the sheathed cable into a castingmold configured to form the brake rotor.
 17. The method of claim 16,wherein the placing comprises locating the insert between an upperpattern of the casting mold and a lower pattern of the casting mold. 18.The method of claim 17, wherein the locating comprises aligning at leastone locator feature on the insert with at least one correspondinglocator feature in each of the upper and lower patterns.
 19. The methodof claim 18, further comprising casting the brake rotor with a moltencasting material, wherein the sheath is configured to shield the cablefrom the molten casting material and prevent the molten casting materialfrom interfering with the sliding movement between the plurality ofwires.
 20. The method of claim 19, further comprising, after thecasting, degating portions of the at least one locator feature on theinsert that extend beyond a periphery of the brake rotor.
 21. The methodof claim 10, wherein the sheathed cable is positioned within the brakecomponent so that, during braking of the motor vehicle, the sheathedcable is configured to dampen a resonant vibration of the brakecomponent via friction generated by sliding movement between the cableand the sheath.